Analysis of Lean Manufacturing
Lean Manufacturing (Lean Manufacturing) is a Massachusetts Institute of Technology
plans to organize several international car (IMVP) expert on Japan,
&quot;Toyota JIT (Just In Time) production,&quot; the praise of the said
fine, that few but not put into extra factors of production, but production at the
appropriate time necessary number of market needs product (or the next process
urgently needed products); interests, that all business activities must be useful and
effective, with the economy. Lean manufacturing is a current industry best
organization system and method of production.
Lean manufacturing is the post-war Japan&#39;s auto industry was the
&quot;resource scarcity&quot; and &quot;more variety, small
batch&quot; the product of market discipline, which is starting from Toyota
It&#39;s long odds, by Kiichiro Toyoda and Ohno resistance to common
first-person efforts to gradually improve until the 60&#39;s formed.
Lean manufacturing is a kind of production to minimize occupied resources and
reduce operating costs, business management and production methods as the main
target, but it also is a concept, a culture. Lean manufacturing is the determination to
pursue the perfect course, is pursuit of excellence in the process, it is the support of a
personal and business life of spiritual power, but also in the never-ending learning
process of getting a state of self-satisfaction. The goal is to strive for excellence,
perfection and never-ending pursuit of the ultimate goal of seven to zero.
The essence of lean manufacturing management process, including the optimization
of organization and management of personnel, efforts to cut the middle management,
to organize the reform of the flat, to reduce non-direct production personnel; push
synchronization of production equalization to achieve zero inventory and flexible
production; implementation the whole production process (including the entire supply
chain) the quality assurance system, to achieve zero non-performing; reduce and
reduce any part of the waste, zero waste; eventually pull in-time production.
Lean manufacturing is characterized by the elimination of all waste, the pursuit of
excellence and continuous improvement. Production processes to remove all useless
things in each of workers and their job is to value the principle of the arrangement,
remove all non-value-added positions. Streamline its core, to streamline product
development, design, production, management does not produce value-added work all
aimed at the best quality, lowest cost and highest efficiency of the market needs the
most rapid response.
The advantages of lean manufacturing methods and significance
Compared with the mass production methods, the Japanese lean manufacturing
methods used in the superiority lies in the following areas:
The necessary human resources - both in product development, production systems,
or other parts of the factory, and factory mass production mode than the minimum can
be reduced to 1 / 2;
New product development cycle - the minimum could be reduced to l / 2 or 2 / 3;
Product inventory in the production process - the minimum could be reduced to the
general level of mass production mode 1 / 10;
Factory space - the minimum could be reduced by mass production mode of 1 / 2;
Finished goods inventory - the lowest mass production mode can be reduced to the
average inventory level of 1 / 4;
Product quality - can greatly;
Lean manufacturing methods are thoroughly pursue the production of rationality,
efficiency, flexibility to produce high-quality products meet the needs of the
production technology and management techniques, many of its basic principles and
methods of manufacturing has a positive meaning. The core of lean manufacturing,
that is, the production planning and control and inventory management, the basic idea,
on the enrichment and development of modern production management theory also
has an important role.
Lean manufacturing management features on
(1) pull (pull) production time (JIT)
The end-user demand for producing a starting point.
Stressed that logistics balance, the pursuit of zero inventory, processing requirements
a process completed parts into the next process immediately.
Organization of production relies on the operation of Kanban (Kanban) for. Kanban
delivery processes from demand information between (billboards of Xingshibuxian,
the key is the ability to transmit information).
Beat production by human intervention, control and logistics to ensure a balance in
production (for each process, the following procedures shall ensure timely supply of).
As a result of pull-type production, production planning and scheduling is essentially
completed by the individual production units themselves, not in the form of a
centralized plan, but during the operation of coordination between production units is
(2) total quality management
Emphasis on quality is produced rather than testing out, from the quality control
process to ensure the final quality.
Production process of quality inspection and control in every process is carried out.
Focuses on training each employee&#39;s quality consciousness, to ensure
timely detection of quality problems.
If found in the production process quality issues, depending on the circumstances, you
can immediately stop production until the problem in order to ensure does not appear
valid non-conforming product processing.
The quality problems, usually related to technical and production organization staff as
a team, with collaboration soon as possible.
(3) Team Work Act (Teamwork)
Each employee at work is not only to carry out orders. More importantly, active
participation, play a role in decision-making and decision support.
Organizations are not fully in accordance with the principles of the team to division of
administrative organizations, but mainly divided according to business relationships.
Team members emphasized the multi-skill, required to be familiar with other staff
within the team, ensuring the smooth coordination.
Evaluation of the performance of team members by working within the
The basic atmosphere of team work is trust, a long-term supervision and control
oriented, while avoiding the work every step of the verification, to improve efficiency.
Team&#39;s organization is changing, different things, create a different team,
the same person may belong to different teams.
(4) CE (Concurrent Engineering)
During the product design and development, will be conceptual design, structural
design, process design, the final demand combined with the fastest speed to ensure the
quality required to complete.
All work related to this project by the team completed. Their own arrangements for
members of the group process itself, but a regular basis or at any time feedback and
coordination to solve the problems.
Based on appropriate information systems tools, feedback and coordination of the
projects. CIM using modern technology, product research and development during the
process of parallel auxiliary projects.
Source: Allied Supply Chain Management Consulting Shanghai Co., Ltd.